Kaizen

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Kaizen Event :SVDO CONTI PRODUCTIVITY
IMPROVEMENT
Team Leader:Deepak(ME).
Team members: Rajesh(ME), Vinayak (Tooling), Chandrasekhar,Shivkumar,Arvind
(Production).
Date : 18th
March 2010

page
Project Scope
Improving productivity
Reducing down time.
Reducing set up rejection.
Reduction of rework.
Define

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Concerns
• Increase in customer requirement :- 90k/month.
• Cycle time :- 70sec.
• Available hours :- 600 hrs.
• Maximum output:- 61K/Month

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Base Line
Metric Baseline Target Entitlement Improvement
Output per
day
2400nos 3100nos 3500nos 46%
Efficiency 120% 150% 170% 40%
Absolute
utilization of
the machine
72% 85% 18%

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Measure
•Average Cycle time running was 70 sec.
Cycle time
81.8
67.5
81.0
62.6 61.7
65.4
70.4 71.5
62.6
66.6
76.9
-
500
1,000
1,500
2,000
2,500
3,000
14-Mar 15-Mar 16-Mar 17-Mar 18-Mar 19-Mar 20-Mar 21-Mar 22-Mar 23-Mar 24-Mar
Day
Qty
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
Cycletime

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Pareto analysis
Dec-Feb
27.0
38.6
48.8
58.2
66.9
75.2
81.7
84.1
86.5 88.5 90.6 92.6 94.4 95.9 97.1 98.1 98.8 99.4 99.8 100.0
0
20
40
60
80
100
120
0.0
20.0
40.0
60.0
80.0
100.0
120.0

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Pareto analysis
Down time Time (hrs) Percentage
Waiting for operator 104.25 27
Mold problem 44.75 12
Machine down 39.5 10
Waiting for mold 36.25 9
Machine cleaning 33.5 9
No load 32 8
Power failure 25.25 7
Mold loading 9.25 2
Cooling connection 9 2
Planned mach stoppage 8 2
Auxiliary Down 8 2
Mold unloading 7.75 2
Planned preventive maintenance 6.75 2
Warming up 6 2
Waiting for tech 4.5 1
Optimization 3.75 1
Mold cleaning 3 1
Delay is start up due to power failure 2 1
Waiting for tool maker 1.75 0
Waiting for clarification QA 0.75 0

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Time analysis
1,Remove
the part
2,Place it on he
table and put runner
in the bin
3,Picking connector and
bobbin for insertion
4,Placing the
connector and bobbin
5,Inserting the
connectors
6,Inserting
bobbin
7,Tapping
the bobbin
8,Blowing
the air
9,Closing the
side core
10,Pressing the
start button
Operator 1
1,Removal of
pin header
2,Removal of
bobbin insert
3,Insertion of insert
for next cycle
Operator 2
1,Visual
inspection
2,Placing
the bobbin
as per
cavity
marking
Operator3
42.81 sec
28.10sec
4.81sec

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Analysis
Time study
4.81
25.5
42.81
12.66
28.1
24 24 24 24 24
0
5
10
15
20
25
30
35
40
45
Independent
function
Operator 1 Operator2 Operator3 Parellel function
Sec
Takt time

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Actions to be taken.
• Increasing the number of trained operator for avoiding the maximum
interruption.
• Improving the cooling connection for leakages to avoid mold down
interruption.
• Increasing the number of inserts.
• Improving the layout for better ergonomics.
• Minimizing the points of rework and bring it near the machine.
• Feasibility for UPS connection so that machine run uninterrupted.

page
Improvements
2,Remove the
part Place it on
he table and
put runner in
the bin
1,Picking connector and
bobbin for insertion
3,Inserting the
connectors
4,Inserting
bobbin
5,Tapping
the bobbin
6,Blowing the air and
closing the side core
7,Pressing the start
button
Operator 1
1,Removal
of pin
header
2,Removal
of bobbin
insert
3,Insertion
of insert
for next
cycle
Operator
2
1,Visual
inspection
2,Placing the bobbin as per cavity
marking
Operator 3
26 sec
23.68sec 4.81sec

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Time after improvement.
Time study
23.68
12.66
26 25.5
4.81
24 24 24 24 24
0
5
10
15
20
25
30
Independent
function
Operator 1 Operator2 Operator3 Parellel function
Sec
Takt time

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Actions initiated
Reason Causes Actions
Waiting for operator
1,Only 2 trained operator per shift.
1, Trained operators so that at
least 4 operators are there
during breaks in a shift for
relieving.
2, Recruiting new operators
Mold problem
1, Cooling leakages.
2,Frequent insert breakages
1, New quick couplers planned.
2, Insert design changed to
avoid frequent breakages
Power failure
1, At least 4 time power break down
causing too much stoppages with
set up rejection.
1, UPS installed for back up in
case of power failure.

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Before and After lay out change
Before After
180
Operator movement for insertion of inserts and removal of the
molded part was difficult and tiresome.
The insertion station brought near operator making the movement
minimum.

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Before and after layout change
Before After
Congested work station making visual inspection difficult Increased the size of the work platform for accommodating all the
operators.

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Production after Kaizen activity
Average productivity presently 75K.
Last month output was 80K.
SVDO PRODUCTIVITY
80835
69956
46785
30623
108.5
75.1
48.7
56.2
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
Feb March April May
Month
Qty
0.0
20.0
40.0
60.0
80.0
100.0
120.0
Cycletime
Cycle time

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Benefits
•Ability to deliver the committed quantity as per customer needs.
•Machine interruption reduced by improving mold down time, installing ups and
training more operators for this project.
Savings April May
$ 3594 2970

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Pending work
• Changing the cooling connectors to good quality couplers:-30days.
• Fitting the new tables with acrylic sheets and lights:-1week.
• Reducing the rework points on the part.

Kaizen

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